Multiple zone cooling apparatus

ABSTRACT

A cooling assembly for a machine tool including at least first and second nozzle rings mounted on the spindle housing, respectively defining first and second coolant conduits and respectively including first and second pluralities of nozzles in fluid communication with the respective conduit. Each first nozzle is oriented with an outlet thereof directed toward a first machining zone containing cutting edges of at last one tool having a first length. Each second nozzle is oriented with an outlet thereof directed toward a second machining zone different from the first machining zone and containing the cutting edges of at least one tool having a second length.

CROSS-REFERENCE TO RELATED APPLICATION

This application is a divisional of U.S. patent application Ser. No.12/821,213 filed Jun. 23, 2010, the entire content of which isincorporated herein by reference.

TECHNICAL FIELD

The application relates generally to CNC machining and, moreparticularly, to a cooling apparatus for a CNC machine using tools ofvarious gauge lengths.

BACKGROUND OF THE ART

Multi-axis CNC (computer numerically controlled) machine tools are oftenused to produce components, for example gas turbine engine components,machined from solid material. This machining process is sensitive to theaccurate delivery of coolant fluid into the machining zone, asdeficiencies in coolant fluid delivery may result in inadequate chipflushing with subsequent degradation of the component's surface finish,tool breakage, and destruction of the component and/or of the machine.

Components are typically machined using cutting tools of variouslengths, usually requiring that the machine operators manually align themachine's coolant delivery nozzles to suit the length of the next toolused. Also, line of sight between the coolant nozzle and the machiningzone changes angularly around the centre of tool rotation during themachining process, and depending on the position of the nozzles, theun-machined material may block or deflect the coolant flow away from thecutting zone.

Improvements in the cooling of CNC machine tools are thus sought.

SUMMARY

In one aspect, there is provided a cooling apparatus for a CNC machinetool having a stationary spindle housing supporting a spindle forrotating about an axis of rotation a selected one of a plurality ofinterchangeable cutting tools including at least a first tool having afirst length and a second tool having a second length different from thefirst length, the apparatus comprising a first nozzle ring mounted onthe spindle housing and at least substantially encircling the spindle,the first nozzle ring defining a first coolant conduit and including aplurality of first nozzles in fluid communication with the first conduitand distributed around the first nozzle ring, each first nozzle beingoriented with an outlet thereof directed toward a first machining zoneextending along the axis of rotation, wherein cutting edges of the firsttool are within the first machining zone when the first tool isinstalled in the spindle, a second nozzle ring mounted on the spindlehousing concentric with the first nozzle ring, the second nozzle ringdefining a second coolant conduit independent from the first coolantconduit and including a plurality of second nozzles in fluidcommunication with the second conduit and distributed around the secondnozzle ring, each second nozzle being oriented with an outlet thereofdirected toward a second machining zone extending along the axis ofrotation and different from the first machining zone, wherein cuttingedges of the second tool are within the second machining zone when thesecond tool is installed in the spindle, and a fluid distribution systemhaving at least first and second configurations, the fluid distributionsystem in the first configuration pressurizing and circulating a coolantfluid from a coolant source to the first conduit only, the fluiddistribution system in the second configuration pressurizing andcirculating the coolant fluid from the coolant source to the secondconduit only.

In another aspect, there is provided a cooling assembly for a machinetool, the assembly comprising an annular manifold including at leastfirst and second concentric fluid passages defined therein, the firstand second passages being sealed from one another, the annular manifolddefining a central longitudinal axis and including first and secondfluid inlets in fluid communication with the first and second passages,respectively, a plurality of first nozzles extending from a front sideof the manifold and distributed around a circumference thereof, each ofthe first nozzles being in fluid communication with the first passageand being oriented such that an outlet thereof is directed toward atleast part of a same first portion of the longitudinal axis, the firstportion being frontwardly offset from the first nozzles, and a pluralityof second nozzles extending from the front side of the manifold anddistributed around the circumference thereof, each of the second nozzlesbeing in fluid communication with the second passage and being orientedsuch that an outlet thereof is directed toward at least part of a samesecond portion of the longitudinal axis, the second portion beingdifferent from the first portion and frontwardly offset from the secondnozzles.

In a further aspect, there is provided a method of machining a part witha machine tool having a stationary spindle housing supporting a spindlefor rotating a selected one of a plurality of interchangeable cuttingtools about an axis of rotation, the method comprising engaging a firstone of the tools with the spindle such that cutting edges of the firsttool are located in a first machining zone extending along a firstportion of the axis of rotation, directing coolant fluid to the firstmachining zone using at least a first nozzle ring mounted on the housingand including first nozzles directing the coolant fluid toward the firstmachining zone, machining the part with the first tool, removing thefirst tool from the spindle, engaging a second one of the tools with thespindle such that cutting edges of the second tool are located in asecond machining zone extending along a second portion of the axis ofrotation different from the first portion, directing the coolant fluidto the second machining zone using at least a second nozzle ring mountedon the housing and including second nozzles directing the coolant fluidtoward the second machining zone, and machining the part with the secondtool.

DESCRIPTION OF THE DRAWINGS

Reference is now made to the accompanying figures in which:

FIG. 1 is a schematic side view of a cooling apparatus installed on aCNC machine;

FIG. 2 is a schematic front view of a ring manifold of the coolingapparatus of FIG. 1;

FIG. 3 is a schematic front view of a body of the ring manifold of FIG.2;

FIG. 4 is a schematic side view of the cooling apparatus of FIG. 1,showing the coolant distribution for each nozzle ring thereof;

FIG. 5 is a schematic partial side view of the cooling apparatus of FIG.4, showing the coolant distribution for a group of nozzles of one of thenozzle rings thereof;

FIG. 6 is a schematic perspective view of an alternate ring manifold ofthe cooling apparatus of FIG. 1;

FIG. 7 is a schematic front view of a body of the ring manifold of FIG.6; and;

FIG. 8 is a schematic front view of a cover of the ring manifold of FIG.6.

DETAILED DESCRIPTION

Referring to FIG. 1, a cooling apparatus 20 is installed on a CNCmachine 10 (only partially shown). The CNC machine 10 includes astationary spindle housing 12 supporting a spindle 14, the spindle 14rotating a selected one of a plurality of cutting tools (not shown).

The cooling apparatus 20 includes a ring manifold 22 which is rigidlyattached to the spindle housing 12 and from which extend a plurality ofcoolant fluid nozzles 24 a,b. In a particular embodiment, the manifold22 is slipped over the housing 12 and slid rearwards, and diametricallyopposed fasteners, for example screws (not shown), are used to clamp themanifold 22 onto the spindle housing 12 and to center it radially withthe spindle's axis of rotation 16. The manifold 22 is located radiallyby means of rigid inlet conduits 26 a,b that extends from the rear ofthe manifold 22.

Alternately, the manifold 22 can be located radially by any otheradequate type of retaining elements, for example by two sheet metalbrackets extending forwards and bolted to the spindle bearing retainer,or by a circumferential ring clamp bearing upon three equally spacedclamping pads that are attached to the rear of the manifold, etc.

It can be seen from FIGS. 4-5 that the tips or outlets 28 of the nozzles24 a,b are located behind the front face of the spindle 14, in order toavoid interference with the machine's capability to automatically changetool assemblies to and from the spindle 14. Each nozzle 24 a,b is angledsuch that its outlet 28 is directed toward a tool to be received in thespindle 14, as will be further detailed below.

Referring to FIG. 2, the ring manifold 22 defines two concentric nozzlerings 30 a, 30 b which, in the embodiment shown, each form a completecircle such as to completely surround the spindle. Each nozzle ring 30a,b is connected to a respective inlet conduit 26 a, 26 b.

Referring to FIG. 3, the manifold 22 includes an annular body 32defining therein two concentric coolant passages 34 a, 34 b, one foreach nozzle ring 30 a,b, each coolant passage 34 a,b forming a conduitfor the coolant fluid. In a particular embodiment, the manifold body 32is machined from a solid annular component, for example made ofaluminium, to form the coolant passages 34 a,b. The manifold body 32also includes a fluid connection 36 a, 36 b between each coolant passage35 a,b and the respective inlet conduit 26 a,b. The coolant passages 34a,b are sealed from each other through an annular gasket 38 that extendstherebetween.

Referring back to FIG. 2, the manifold 22 also includes an annular cover40, which engages the manifold body 32 and also seals the coolantpassages 34 a,b from one another. In a particular embodiment, themanifold cover 40 is bolted to the body 32; however, alternate means ofattachment are also possible. The manifold cover 40 includes a series ofthreaded holes 42 a, 42 b defined therethrough in each of the nozzlerings 30 a,b, in communication with the respective coolant passage 34a,b. Commercially available compression fittings 44 (see FIG. 1) arescrewed into the threaded holes 42 a,b and receive the coolant nozzles24 a,b, which are locked in place once their length and orientation isadjusted. In the embodiment shown, the threaded holes 42 a,b of eachnozzle ring 30 a,b, and as such the coolant nozzles 24 a,b thereof, areequally angularly spaced apart. Alternately, a different distribution ofthe nozzles 24 a,b can be provided, for example having the nozzles 24a,b distributed around the circumference of the manifold 22 but withdifferent distances between adjacent nozzles such that the nozzles 24a,b are not equally circumferentially spaced apart.

The nozzle rings 30 a,b provide individual coolant delivery circuitsthat are independent from one another. Each inlet conduit 26 a,b isconnected to a coolant source 46 through a fluid distribution system 48,which pressurizes the coolant fluid and delivers it to a selected one orboth of the nozzle rings 30 a,b. The fluid distribution system 48operates based on “On” and “Off” commands (M-codes) contained within theoperating instructions or part program that is programmed into, andexecuted by, the CNC machine tool. For example, the “On” commands may beM08 for the inner nozzle ring and M20 for the outer nozzle ring and the“Off” command may be M09 for both nozzle rings; however, any availableM-codes that have not been otherwise assigned by the machine toolbuilder or operator may alternately be used. During operation of themachine tool these coolant command M-codes can be programmedindividually or in any combination.

In a particular embodiment, the fluid distribution system 48 includes apump (not shown) in fluid communication with the coolant source 46 and asolenoid actuated valve (not shown) providing a selective connectionbetween each of the inlet conduits 26 a,b and the pump, the valve beingactuated by the CNC commands. Alternately, more than one pump may beprovided, and/or the inlet conduits 26 a,b can be connected to thecorresponding pump(s) through respective valves actuatable through theCNC commands.

Referring to FIG. 4, each nozzle ring 30 a,b is assigned a specificrange of tool lengths L₁, L₂ to cover. In the illustrated example, theinner nozzle ring 30 a is assigned to a first tool length range L₁, forexample 12 to 14 inches, and the outer nozzle ring 30 b is assigned to asmaller, second tool length range L₂, for example 8 to 11 inches.

For each range of tool lengths L₁, L₂, a machining zone M₁, M₂ can bedefined along the axis of rotation 16 of the spindle 14, which alsocorresponds to the longitudinal axis of the manifold 22. The machiningzone M₁, M₂ contains the cutting edges of all of the tools within thatrange of tool lengths L₁, L₂, when each tool is installed in the spindle14. Thus, each nozzle 24 a extending from the inner ring 30 a isoriented with the outlet 28 thereof directed toward at least a portionof the first machining zone M₁, where the cutting edge(s) of every toolwithin the first range of tool lengths L₁ are located, and each nozzle24 b extending from the outer ring 30 b is oriented with the outlet 28thereof directed toward at least a portion of the second machining zoneM₂, where the cutting edge(s) of every tool within the second range oftool lengths L₂ are located. The machine tool programmer thus programsthe selection of the nozzle ring 30 a,b that is suitable for the lengthof the tool that he/she is programming for use next.

Although not shown, the tool lengths may alternately be distributed suchthat a first range corresponds to a first one of the nozzle rings, asecond range to a second one of the nozzle rings, and a third,intermediate range is associated with both nozzle rings, so that when atool from the third range is selected, both nozzle rings are actuated todirect the coolant fluid thereon. In that case, the nozzles of the firstring direct the coolant fluid along a first machining zone, the nozzlesof the second ring direct the coolant fluid along a second machiningzone which abuts the first machining zone, and the third machining zoneis contained within the combination of the first and second machiningzones.

The nozzles 24 a,b are rigid, for example made of stainless steeltubing, and their orientation is pre-set during installation of theapparatus 20 on the machine tool 10; thus, no manual adjustment isnecessary during the machining process, prior to, or following,automatic tool changes. The cooling apparatus 20 thus allows fordifferent gauge lengths of tools to be lubricated through simple CNCcommands, and provides for automatic tool changes without removing oradjusting the coolant nozzles.

Referring to FIG. 5, the nozzles 24 a,b of each ring 30 a,b (only theinner nozzle ring 30 a being shown here) are arranged in at least twogroups 50 (only one of which is shown) that are distributed around thecircumference of the nozzle ring 30 a,b, for example by having thegroups 50 being at least substantially angularly spaced apart, and/or byhaving the groups 50 distributed in pairs of groups located indiametrically opposed locations around the nozzle ring 30 a,b. In aparticular embodiment, each group 50 includes three (3) nozzles 24 a,b.The nozzles 24 a,b within a same group 50 are targeted to a differentportion of the respective machining zone M₁, M₂. In the embodimentshown, the different portions targeted by the nozzles 24 a of the samegroup 50 together cover the entire machining zone M₁, such that eachgroup 50 of nozzles provides coolant fluid along the entire machiningzone M₁. The different groups 50 provide coolant fluid from differentangular positions around the axis of rotation 16, in order to maintaincoolant fluid delivery when the cooling fluid delivered by the nozzles24 a,b from one of the groups 50 is obstructed by un-machined material.The cooling apparatus 20 thus delivers cooling fluid targeted on severalpoints along the cutting edges of each tool used, and from multipledirections around the circumference of the tool, thus facilitating themachining of contoured surfaces with the side of the tool duringsimultaneous multi-axis machining.

The orientation of each nozzle 24 a,b can be confirmed by sliding agauge-rod which is a precise fit with the inside of the nozzle in thenozzle outlet 28, the free end of the rod indicating where the projectedcoolant will contact the tool. Computer simulation can alternately beused to predict the contact point between the coolant and the tool. Oncethe original orientation of the nozzle 24 a,b is selected, it is lockedand remains the same, i.e. it does not change during the machiningprocess.

Referring to FIG. 6, a ring manifold 122 according to an alternateembodiment is shown. In this embodiment, the ring manifold 122 is in theform of an open ring, i.e. has a substantially “C”-shaped configuration,such that it substantially, but not completely, surrounds the spindle 14when it is rigidly attached to the spindle housing 12. The manifold 122includes a body 132 and a cover 142, and the manifold cover includes aplurality of compression fittings 44 attached thereto for each receivinga coolant fluid nozzle (not shown). As in the previous embodiment, themanifold 122 is attached to the spindle housing 12 such that the tips ofthe nozzles are located behind the front face of the spindle 14, inorder to avoid interference with the machine's capability toautomatically change tool assemblies to and from the spindle.

Referring to FIG. 7, the manifold 122 defines three concentric nozzlerings 130 a, 130 b, 130 c, each being connected to a respective inletconduit in fluid communication with the coolant source (not shown). Themanifold body 132 includes three concentric coolant passages 134 a, 134b, 134 c, one for each nozzle ring 130 a,b,c, each coolant passage 134a,b,c forming a conduit for the coolant fluid. In a particularembodiment, the manifold body 132 is machined from a solid open ringcomponent to form the coolant passages 14 a,b,c. The manifold body 132also includes a fluid connection 136 a, 136 b, 136 c between eachcoolant passage 134 a,b,c and the respective inlet conduit (not shown).The coolant passages 134 a,b,c are sealed from each other throughannular gaskets 138 a, 138 b that extend between adjacent ones of thecoolant passages 134 a,b,c.

Referring to FIG. 8, the manifold cover 140 engages the manifold body132 and also seals the coolant passages 134 a,b,c from one another. Themanifold cover 140 includes a series of threaded holes 142 a, 142 b, 142c defined therethrough in each of the nozzle rings 130 a,b,c, incommunication with the respective coolant passage 134 a,b,c. Thecompression fittings 44 (see FIG. 6) are screwed into the threaded holes142 a,b,c and receive the coolant nozzles, which are locked in placeonce their length and orientation is adjusted. In the embodiment shown,the threaded holes 142 a,b,c of each nozzle ring 130 a,b,c, and as suchthe coolant nozzles thereof, are equally angularly spaced apart withineach one of two diametrically opposed portions of the manifold 122.

As in the previous embodiment, the nozzle rings 130 a,b,c provideindividual coolant delivery circuits that are independent from oneanother. Each nozzle ring 130 a,b,c receives coolant fluid from thefluid distribution system 48 which operates based on the “On” and “Off”commands (M-codes) contained within the part program of the CNC machinetool. As in the previous embodiment, each nozzle ring 130 a,b,c isassigned a specific range of tool lengths to cover, such that thenozzles of each nozzle ring 130 a,b,c are oriented with the outletthereof directed toward a portion of the respective machining zone. Asin the previous embodiment, the nozzles of each ring 130 a,b,c arearranged in at least two groups that are distributed around thecircumference of the nozzle ring, with the nozzles within a same groupbeing targeted to a different portion of the respective machining zone.

In use, when machining a part with the CNC machine, a first tool isautomatically selected through a corresponding command in the partprogram, and engaged with the spindle 14. Coolant fluid is directed onthe machining zone of the first tool through the nozzles of the ring orrings 30 a,b, 130 a,b,c which are assigned to the length rangecorresponding to the length of the first tool selected, the nozzle ringor rings 30 a,b, 130 a,b,c being actuated through command(s) of the partprogram, and the part is machined with the first tool. When the firsttool is automatically changed for a second tool, coolant fluid isdirected on the machining zone of the second tool through the nozzles ofthe ring or ring(s) 30 a,b, 130 a,b,c which are assigned to the lengthrange corresponding to the length of the second tool selected, which mayor may not be the same as that of the first tool. Depending on the toollength, one or more of the nozzle rings 30 a,b, 130 a,b,c are activated,such that the corresponding machining zone receives coolant fluid. Thenozzle ring(s) 30 a,b, 130 a,b,c are deactivated when required alsothrough command(s) in the part program.

The above described cooling apparatus thus maintains coolant flow at themachining zone, and allows for unattended operation even through the useof tools of different lengths. The installation of the manifold 22, 122on the stationary spindle housing 12 prevents the manifold 22, 122 fromhaving an influence upon the practical operating speed and the dynamicbalance of the spindle 14. The manifold 22, 122 can be retrofitted toany machine tool, whether its spindle 14 is attached to a linear axis, atilting axis, or a rotary axis.

The above description is meant to be exemplary only, and one skilled inthe art will recognize that changes may be made to the embodimentsdescribed without departing from the scope of the invention disclosed.For example, the nozzle rings 30 a,b, 130 a,b,c may be defined bydistinct tubes instead as by coolant passages of a same manifold 22,122. Also, more than three nozzle rings may be provided. Othermodifications which fall within the scope of the present invention willbe apparent to those skilled in the art, in light of a review of thisdisclosure, and such modifications are intended to fall within theappended claims.

The invention claimed is:
 1. A method of machining a part with a machinetool having a stationary spindle housing supporting a spindle forrotating a selected one of a plurality of interchangeable cutting toolsabout an axis of rotation, the method comprising: engaging a first oneof the tools with the spindle such that cutting edges of the first toolare located in a first machining zone extending along a first portion ofthe axis of rotation; directing coolant fluid to the first machiningzone using a first nozzle ring mounted on the housing and includingfirst nozzles directing the coolant fluid toward the first machiningzone; machining the part with the first tool; removing the first toolfrom the spindle; engaging a second one of the tools with the spindlesuch that cutting edges of the second tool are located in a secondmachining zone extending along a second portion of the axis of rotation,the second portion of the axis of rotation and the first portion of theaxis of rotation at least partially overlapping; directing the coolantfluid to the second machining zone using the first nozzle ring and asecond nozzle ring simultaneously, the second nozzle ring mounted on thehousing and including second nozzles directing the coolant fluid towardthe second machining zone; and machining the part with the second tool.2. The method as defined in claim 1, wherein directing the coolant fluidto the first machining zone includes activating coolant circulationthrough the first nozzle ring using a first machine command included ina program activating the machine tool, directing the coolant fluid tothe second machining zone includes activating coolant circulationthrough the second nozzle ring using a second machine command includedin the program, and further including deactivating the coolantcirculation through the nozzle rings using a third machine commandincluded in the program after machining the part.
 3. The method asdefined in claim 1, further comprising, after machining the part withthe second tool: removing the second tool from the spindle; engaging athird one of the tools with the spindle such that cutting edges of thethird tool are located in a third machining zone extending along a thirdportion of the axis of rotation different from the first and secondportions; directing the coolant fluid to the third machining zone usingat least a third nozzle ring mounted on the housing and including thirdnozzles directing the coolant fluid toward the third machining zone; andmachining the part with the third tool.
 4. The method as defined inclaim 1, wherein directing the coolant fluid to the first machining zoneincludes directing the coolant fluid on a same set of points on thefirst machining zone from at least two different angular positionsaround the spindle, and directing the coolant fluid to the secondmachining zone includes directing the coolant fluid on a same set ofpoints on the second machining zone from at least two different angularpositions around the spindle.